Programmable routing module

ABSTRACT

A programmable routing module is disclosed for interconnecting field wiring with a control system. The routing module includes a field connection to connect field signals from a controlled process to the routing module, an I/O connection to connect I/O signals from the control system to the routing module, and a configurable interconnection system that selectively couples particular field and I/O signals with one another.

REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. ProvisionalPatent Application Ser. No. 60/785,550, filed Mar. 24, 2006, entitledPROGRAMMABLE I/O INTERCONNECTING ADAPTER, and Provisional PatentApplication Ser. No. 60/793,814, filed Apr. 21, 2006, entitledPROGRAMMABLE ROUTING MODULE, the entirety of which are herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to control systems and moreparticularly to programmable routing modules for interconnecting controlsystem I/O with machines or other controlled processes.

BACKGROUND OF THE INVENTION

Control systems or industrial controllers are used for controllingindustrial processes such as machines, manufacturing equipment, andother factory automation apparatus. An industrial controller receivesvarious process variables or other inputs representative of the statusof a controlled process, and generates outputs according to a controlprogram or routine to control the process to one or more desiredsetpoints, where the inputs and outputs can be binary, (e.g., on oroff), and/or analog assuming a continuous range of values. The controlsystem, moreover, can be distributed with two or more modules performingvarious functions, such as I/O modules interfacing with field devicesfor sending and receiving outputs and inputs, control modules that runthe control program and communicate with I/O modules, etc. In such adistributed control system (DCS), input signals received from thecontrolled process and the outputs transmitted to the process can passthrough one or more input/output (I/O) modules, which serve as anelectrical interface between the controller and the controlled process,and can be located proximate or remote from the controller. The modulesof a DCS can be spatially distributed along a common communication linkin several racks, whereby certain I/O modules can be located close tothe controlled process proximate a portion of the control equipment, andremote from the remainder of the control system. Data is typicallycommunicated between modules over a common communication link, ornetwork using a communications protocol.

One problem in conventional control systems is physical interconnectionof the field signals of the controlled process with the I/O modules ofthe control system. For many industrial control applications, such ascontrol of machines or processes involving large numbers of input andoutput signals, the control system I/O signal terminals must beconnected by wires to a number of different sensors, actuators,machines, etc. FIG. 1 illustrates a conventional industrial system 2having a number of machines 10 constituting a controlled process 14 thatsend or receive various field signals 12, including outputs and/orinputs, where the field signals 12 may be analog and/or digital signals.The controlled process 14 is operated by a control system 20 thatincludes control processing elements (not shown) as well as I/Ocomponents 22 for coupling analog and/or digital I/O signals 24associated with the controlled process 14. Wiring terminals 30 areprovided as an intermediate connection point for connecting particularfield signals 12 and I/O signals 24 with one another such that thecontrol system 20 receives the necessary inputs to ascertain thepertinent operating conditions associated with the controlled process 14and such that the controlled process 14 receives the necessary outputcontrol signals from the control system 20 for controlling the process14 according to a control program or routine. In the illustrated system2, wiring terminals 30 provide a location from which the wiring for thefield and/or I/O signals 12, 24 may be grouped as needed into cables orthe like to facilitate orderly signal interconnection. However, thisconventional interconnection approach requires manual connection of eachsignal wire 12, 24 to the correct terminal 30. Moreover, thisinterconnection system is difficult to troubleshoot or reconfigure, andthe terminal connections must be carefully documented.

In order to simplify control system interconnection, the wiringterminals 30 may be replaced by custom circuit boards having a series ofcable connectors with fixed traces routed on the board to provide aspecific set of interconnections between I/O cabling and field signalcabling. However, reconfiguration of the system signal interconnectionsin such an approach requires layout of a new printed circuit board. Inthis regard, if a component of a controlled process is upgraded, thewiring interconnection requirements may change, and a new custom printedcircuit board would be needed. Thus, the conventional control systemwiring techniques are customized for a given control application, andare not well suited to troubleshooting or reconfiguration. Furthermore,the wiring terminals 30 and customized printed circuit boards add costand complexity to the overall industrial system 2, whereby there is aneed for improved routing apparatus for interconnecting field wiringfrom a controlled process with I/O wiring of a control system.

SUMMARY OF INVENTION

Various aspects of the present invention are now summarized tofacilitate a basic understanding of the invention, wherein this summaryis not an extensive overview of the invention, and is intended neitherto identify certain elements of the invention, nor to delineate thescope thereof. Rather, the primary purpose of this summary is to presentsome concepts of the invention in a simplified form prior to the moredetailed description that is presented hereinafter. The inventionrelates to programmable routing modules and programming tools andmethods by which signal routing is facilitated in the interconnection offield signals of a controlled process with I/O signals of a controlsystem.

In accordance with one or more aspects of the present invention, aprogrammable routing module is provided for interconnecting field wiringwith a control system. The routing module includes a field connectionsuch as board mounted cable connectors that connect field signals fromthe controlled process to the routing module, as well as an I/Oconnection for connecting I/O signals from the control system to themodule. The routing module further includes an interconnection systemthat is configurable to connect a desired set of field and I/O signalswith one another. In certain embodiments, the configurableinterconnection system can be configured more than once (e.g.,reconfigurable), and other implementations may provide one timeconfiguration capabilities.

In one possible implementation, the module is comprised of a printedcircuit board (PCB) with holes formed between top and bottom sides, andthe configurable interconnection system includes conductive padsproximate the holes on the top and bottom sides with pads on oppositeends of the individual holes being electrically isolated and spaced fromone another. The interconnection system further comprises conductivetraces on the top and bottom sides of the board that couple the I/O andfield signals to select groups of the conductive pads, where the pads onopposite ends of the individual holes are connected by conductive tracesto a unique pair of signals. Conductive pins are positioned in specificholes to electrically connect pads on opposite ends so as toelectrically connect the corresponding signals. In this manner,insertion of pins in the proper locations provides configuration of thePCB to implement a desired set of routing module interconnectionsinvolving selected input and/or output field signals of the controlledprocess and selected input and/or output I/O signals of the controller.The pins may be soldered into the board for one time configurability ormay be removable to allow reconfiguration of the routing module.

In another embodiment, the routing module includes programmable logic toselectively operatively couple particular field and I/O signals with oneanother according to a defined set of interconnections. The programmablelogic, moreover, may be operative to store a code representing theconfigured set of interconnections, and may be further operative toperform a Boolean operation on particular field and/or I/O signals togenerate at least one output and to provide the output to the fieldconnection or the I/O connection. In thus manner, the module may beconfigured to perform safety interlock or other Boolean logic typeoperations in order to further simplify the interconnection of thecontroller with the controlled process and to reduce the amount ofexcess wiring associated therewith. The routing module may also includea communications interface for connection of the programmable logicdevice with an external device for programming the module and/or forretrieving the code.

In addition, the configurable routing module may have one or more drivercircuits with driver inputs and outputs that can be selectivelyconnected to particular field or I/O signals for buffering analogsignals, as well as routable logic circuits to perform Booleanoperations. In certain possible embodiments, moreover, the module mayinclude an expansion connection for routing one or more of the connectedfield and/or I/O signals to a second programmable routing module.Furthermore, the field and I/O connections may be made by any suitablemeans, such as cable connectors for easy connection with cables from thecontrolled process and control system I/O, and the I/O connection in oneexemplary embodiment may include a plurality of rigid board mounted pinsextending outward from one side of the board, which are located in apredetermined pattern to allow insertion of extended portions of thepins into receiving sockets of one or more I/O terminal bases orterminal blocks of the control system for electrical connection to aplurality of I/O signals, thereby reducing the cost of signal wiring onthe I/O side of the routing module.

Further aspects of the invention relate to methods for configuring arouting module for interconnecting field wiring with a control system.The method comprises defining a set of routing module interconnectionsbetween I/O and/or field signals using a software configuration tool,and configuring the routing module by providing the set of routingmodule interconnections to a programmable logic device on the routingmodule to establish a desired set of interconnections between aplurality of field signals from a controlled process and a plurality ofI/O signals from the control system. In one example, the method mayfurther include generating a code representing the set of routing moduleinterconnections, and storing the code in the programmable logic device.For electronically programmable routing modules, the definition of theinterconnections may comprise obtaining a code from the routing modulethat represents a current set of interconnections, generating agraphical representation of the current set of interconnectionsaccording to the code, and allowing a user to modify theinterconnections to define a new set of routing module interconnectionsbetween I/O and/or field signals, with the new set of interconnectionsbeing provided to the programmable logic for reconfiguration of therouting module.

Still further aspects of the invention provide a system for configuringa routing module, including means for defining a set of routing moduleinterconnections between I/O and/or field signals using a softwareconfiguration tool, and means for configuring the routing module byproviding the set of routing module interconnections to a programmablelogic device on the routing module to establish a desired set ofinterconnections between a plurality of field signals from a controlledprocess and a plurality of I/O signals from the control system.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description and drawings set forth certain illustrativeimplementations of the invention in detail, which are indicative ofseveral exemplary ways in which the principles of the invention may becarried out. The illustrated examples, however, are not exhaustive ofthe many possible embodiments of the invention. Other objects,advantages and novel features of the invention will be set forth in thefollowing detailed description of the invention when considered inconjunction with the drawings, in which:

FIG. 1 is a simplified system diagram illustrating a conventionalcontrolled process connected with a control system using wiringterminals;

FIG. 2A is a system diagram illustrating an exemplary programmablerouting module according to various aspects of the present inventionwith field and I/O signal connections for coupling signals between acontrolled process and a control system, and having a configurableinterconnection system that selectively couples particular field and I/Osignals with one another;

FIG. 2B is a detailed schematic diagram illustrating exemplary routabledriver circuits in the routing module of FIG. 2A;

FIG. 2C is a detailed schematic diagram illustrating exemplary routablelogic circuits in the routing module of FIG. 2A;

FIG. 3A is a top plan view illustrating a first exemplary embodiment ofthe programmable routing module having a manually configurableinterconnection system with conductive traces and pads;

FIG. 3B is a partial sectional upper perspective view illustrating aportion of the module of FIG. 3A with an exemplary conductive trace andconductive pads on a top side thereof;

FIG. 3C is a partial sectional lower perspective view illustrating theexemplary portion of the module of FIGS. 3A and 3B with exemplaryconductive traces and conductive pads on a lower side thereof;

FIG. 3D is a partial sectional side elevation view of a portion of therouting module of FIGS. 3A-3C with conductive pads on either end of anexemplary hole through the module board where the top and bottom pads ofthe illustrate hole are electrically disconnected and spaced from oneanother;

FIG. 3E is a partial sectional side elevation view of the exemplaryportion of the routing module of FIG. 3D with a conductive pin insertedin the hole to electrically connect the upper and lower pads and thesignals associated therewith;

FIG. 4 is a top plan view illustrating a second exemplary embodiment ofthe programmable routing module having a programmable logic device (PLD)providing programmatic configuration of the routing module for selectiveelectrical coupling of particular field and I/O signals with one anotheraccording to a defined set of interconnections;

FIG. 5 is a perspective view illustrating a third exemplary embodimentof the programmable routing module in which the I/O connection includesa plurality of pins extending outward from one side of the routingmodule board for easy connection with I/O terminal bases of the controlsystem; and

FIGS. 6-8 are flow diagrams illustrating various methods for programminga configurable routing module using a software programming tool or otherrouting module configuration system in accordance with other aspects ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the figures, several embodiments or implementations ofthe present invention are hereinafter described in conjunction with thedrawings, wherein like reference numerals are used to refer to likeelements throughout, and wherein the various features are notnecessarily drawn to scale. FIG. 2A depicts a system 52 having aprogrammable routing module 100 in accordance with certain aspects ofthe invention. The system 52 also includes the controlled process 14formed by the machines 10 and the field signals 12 associated therewithas previously described in connection with the system 2 of FIG. 1 above,as well as a control system 20 with I/O 22 for coupling I/O signals 24.The exemplary programmable routing module 100 in FIG. 2A is employed inthe system 52 to connect the field wiring signals 12 of the controlledprocess 14 with the I/O signals 24 of the control system 20, where theinterconnected signals 12, 24 can be inputs, outputs or both, and thesignals 12, 24 can be analog, digital, or both. The module 100 includesa field connection 102, in this case a plurality of N field connectors102 that are mounted on a module printed circuit board to connect aplurality of the field signals 12 from the process 14 to the routingmodule 100, and further includes an I/O connection 104, such as one ormore board mounted I/O connectors adapted to connect a plurality of theI/O signals 24 from the control system 20 to the module 100. In onepossible implementation, the field connection 102 comprises one or moreboard mounted cable connectors operatively coupleable to field wiringcables to couple the signals 12 from the controlled process 14 and theI/O connection comprises 104 includes one or more board mounted cableconnectors operatively coupleable to I/O wiring cables to connect thesignals 24. In another implementation illustrated and described below inconnection with FIG. 5, the I/O connection 104 includes rigid boardmounted conductive pins extending down from the bottom of the modulecircuit board to facilitate direct connection of the module 100 to oneor more I/O terminal bases 22 of the control system 20 withoutadditional I/O cabling.

The programmable routing module 100 includes a configurableinterconnection system 110 coupled with the field and I/O connections102, 104, which is selectively configurable to selectively operativelycouple particular field and I/O signals 12, 24 with one another. Thesystem 110 may be a passive, manually configurable implementation, suchas illustrated and described further in connection with FIGS. 3A-3Ebelow, or may include a programmable logic device (PLD), processor, orother electronically configurable system for selective signal routing.The module 100 thus provides cost reduction and simplification of thewiring used to connect the control system 20 to the controlled process14 and further allows use of standardized wiring cables and adaptabilityto changes in wiring requirements as the control system 20 or themachines 10 of the controlled process 14 may change.

The module 100 may optionally include a power connection 112 forproviding external power to the module 100, along with any associatedpower conversion circuitry (not shown) for powering any active circuitsof the module. Other implementations may be passive, in which case thepower connection 112 may be omitted. The module 100, in this regard, mayoptionally include active driver circuits 120 for buffering analogsignals being routed by the module 100 (FIG. 2B below), and/or routablelogic circuitry 130 for performing Boolean operations to generateoutputs based on the states of digital input signals 12, 24, where thedrivers 120 and logic circuits 130 are coupled with the interconnectionsystem 110 allowing the configurable interconnections to include routingsignals 12, 24 to or from the drivers 120 and the logic 130, where thecircuits 120, 130 may be powered from external power via the powerconnection 112. These optional features 120, 130, in turn, furtherimprove the flexibility and adaptability of the module 100 by providingfor selective buffering of analog signals and/or Boolean operations ondigital signals, for instance, allowing safety interlock functionalitywithout any additional wiring.

Where the configurable interconnection system 110 includes programmablelogic, moreover, a communications interface 140 may be operativelycoupled with the interconnection system 110 on the module 100 forcommunicative connection of the logic device with an external device,such as direct communication with a computer 40 (e.g., via a universalserial bus (USB) or other suitable connection 140) or communication withother external device(s) (not shown) through the interface 140 and anexternal network 42. The module 100, moreover, may also include one ormore expansion connections 150, such as a cable connector,board-to-board connector, etc., coupled to the field connection 102 andto the I/O connection 104 either directly or through the interconnectionsystem 110, to allow connection to a second programmable routing module100 to route at least some of the field and/or I/O signals 12, 24 to thesecond module 100. In this regard, the signals 12, 24 may beconfigurably provided to the expansion connection 150 directly from thefield or I/O connections 102, 104, or through the drivers 120 or logic130 by programmable routing using the configurable interconnectionsystem 110.

FIG. 2B illustrates further details of the exemplary routable drivers120 including several routable driver circuits 122 in the routing module100. The driver circuits 122 each include an input selectivelyelectrically coupleable via the interconnection system 110 to aparticular field or I/O signal 12, 24, as well as an output that is alsoselectively electrically coupleable via the system 110 to anotherparticular field or I/O signal 12, 24. The driver circuits 122 may thusprovide analog signal buffering, level shifting, amplification, etc.,for operatively connecting an analog signal output by the control system20 or the controlled process 14 in order to provide a suitable analoginput signal for connection to the controlled process 14 or the controlsystem 20.

FIG. 2C further illustrates the routable logic 130 of the exemplarymodule 100, including several logic circuits 132 individually includingtwo or more inputs and one or more outputs that are each electricallycoupleable to particular field and/or I/O signals 12, 24 via theconfigurable interconnection system 110, where the logic circuits 132perform a Boolean operation on the inputs to derive the output(s). Thelogic circuits 132 may be of any form and construction, wherein theexamples of FIG. 2C provide interlock safety gating functionality. Otherlogic circuits are possible, for instance, including individuallyroutable AND, OR, and inverter gates so that a user may selectivelycreate any desired Boolean function by selective configuration of theinterconnection system 110.

Referring now to FIGS. 3A-3E, a first exemplary programmable routingmodule 100 a is illustrated with a printed circuit board (PCB) structure160, in which the interconnection system 110 includes conductive traces164 and conductive pads 162, and the module is manually configured byinstalling conductive pins 168 in certain thru-holes 166 of the board160. This implementation provides the field and I/O connections 102, 104in the form of board mounted cable connectors, such as D-sub connectors,for easy coupling with wiring cables from the controlled process 14 andthe I/O 22 of the control system 20 (FIG. 2A), although other types offield and I/O connections 102, 104 can be provided. The module 100 a,moreover, may optionally include drivers 120 and/or logic circuits 130as described above, although not a requirement. As best illustrated inFIGS. 3B-3E, the printed circuit board 160 includes holes 166 formedbetween top and bottom sides 160 a, 160 b of the board 160, and theconfigurable interconnection system 110 is comprised of a plurality ofconductive pads 162 a and 162 b formed on top and bottom sides of theboard, respectively, with the pads 162 being proximate the holes 166 andwith pads 162 a and 162 b on opposite ends of the individual holes 166being electrically isolated and spaced from one another (FIG. 3D). Theconductive traces 164 a and 164 b are formed on the top and bottom sides160 a and 160 b, respectively, and are individually connected (routed)to one of the field or I/O connections 102, 104 such that the I/O andfield signals are individually coupled to select groups of theconductive pads 162 with pads 162 a and 162 b on opposite ends of theholes 166 being connected by conductive traces 164 a and 164 b,respectively, to a unique pair of signals 12, 24. To interconnect agiven pair of signals 12, 24, a conductive pin 168 is positioned asshown in FIG. 3E in the corresponding hole 166 to electrically connect(short) the upper and lower pads 162 a and 162 b on opposite endsthereof, thereby electrically connecting the corresponding signals 12,24. In this fashion, a desired set of routing module interconnectionscan be configured by inserting pins 168 in the appropriate holelocations in the interconnection system 110. The pins 168 may then beoptionally soldered into place for one-time configuration of the module100 a, or the conductive pins may be removable allowing reconfigurationof the routing module 100 a.

In another possible implementation, a similar matrix of traces may beused to construct a PCB based configurable interconnection system 110,with fuses positioned between traces 164 corresponding to each pair ofroutable field and I/O signals 12, 24, wherein the system 110 could beconfigured or programmed by application of suitable voltages to specificpairs of field and I/O signal connections to blow (open-circuit) fusesassociated with signals that are not desired to be connected. In thismanner, a one-time configurable routing module can be programmed orcustomized for a given interconnection application without the need todesign and route a specific PCB layout. In this scenario, if asubsequent routing change is desired, and new module could be similarlyprogrammed by blowing an appropriate set of fuses to implement the newset of routing interconnections.

Referring now to FIG. 4, another exemplary implementation provides anelectronically programmable routing module 100 b in which theconfigurable interconnection system 110 comprises a programmable logic(PLD) 170, which can be any form of user configurable hardware,software, firmware, etc., such as programmable logic, a processor systemwith or without external memory, a PGA, a ROM, an ASIC, etc., which mayinclude both analog and digital circuitry, such as routable drivers 120and/or routable logic 130. In the illustrated example, the PLD 170 canbe programmed to implement the routable logic functions 130 internally,and provides for configurable routing to external drivers 120 on themodule 100 b. In the example of FIG. 4, the PLD 170 is coupled with thefield and I/O connections 102, 104 and is configurable or programmableto operatively interconnect any two or more of the signals 12, 24associated therewith by direct electrical connection or other operativeinterconnection according to establish a desired set ofinterconnections. In this respect, the PLD can provide for directelectrical connection thereof or may operate external connectioncircuitry (e.g., switches, fuses, etc.), so as to selectivelyoperatively couple particular field and I/O signals 12, 24 with oneanother according to a defined set of interconnections.

In one example, the PLD 170 is one-time programmable, and in anotherpossible embodiment, the PLD 170 and hence the module 100 b may bereconfigured any number of times. The module 100 b also preferablyincludes a communications interface 140 such as a universal serial bus(USB) or other suitable communications means, by which the PLD 170 canbe programmed by an external device (e.g., computer 40 in FIG. 2A)coupled directly to the module 100 b or through a network 42 (FIG. 2A).In addition, the module 100 b may be adapted to store a code (e.g., ahexadecimal value, whether encrypted or not) that represents the set ofprogrammed interconnections, where the code may be generated by anexternal programming/configuration tool and stored in the PLD 170, orthe PLD 170 may generate and save the code after being configured.Thereafter, the code may be accessible by an external device, such as asoftware configuration system or tool, from which the tool can ascertainthe current configuration of the module 100 b (with the appropriate keyif encrypted and/or with the appropriate password if securityprotected).

FIG. 5 illustrates another possible implementation of a programmablerouting module 100 c comprising a printed circuit board 160 where theI/O connection 104 comprises a plurality of board mounted rigid pinsextending downward from the bottom side 160 b of the board 160 forconnection with push-pin type terminal bases or terminal blocks 22 ofthe control system 20. In this embodiment, the pins 104 are spaced in apredetermined pattern to allow insertion of the extended portionsthereof into receiving sockets 22 a of the terminal bases 22 forelectrical connection to a plurality of I/O signals 24, and the top side160 a of the module 100 c includes d-sub or other suitable connectors102 for field wiring. In this regard, the use of the board mounted pins104 as the I/O connection for the module 100 c advantageously saves costand space since no additional wiring or cables are needed for couplingthe I/O signals 24 of the control system 20.

Referring now to FIGS. 6-8, further aspects of the invention providemethods and systems for configuring a programmable routing module 100for interconnecting field wiring 12 with a control system 20, wherethese figures provide flow diagrams 200, 300, and 400 to illustratevarious exemplary module programming methods. The methods 200, 300, and400 can advantageously be implemented in routing module configurationsoftware tools which can be a page served by the PLD 170 of the module100 or a utility in a PC 40 (FIG. 2A) that acts as a master to themodule 100 or other suitable implementation. Such software may also beadapted to read a configuration file from RSL5k5, RSNetWorx, or othercontrol software packages, or can be manually loaded with catalog numberinformation about the I/O modules 22 used in a given control system toassist a user in configuring the interconnections for a given module100. The software, moreover, can generate output files in a standard CADfile format or other suitable format to provide a graphicalrepresentation of the set of defined interconnections, such as wiringdiagram information including graphics of the relevant connectorsforming the field or I/O connections 102, 104, preferably includinglogical address cross references to the I/O points. In operation,moreover, the configuration software may comprise any suitable userinterface, such as a graphical user interface (GUI) with of multiplepages following a logical progression through the steps required toconfigure and initialize a programmable routing module 100.

In general, the methods of the invention include definition of a set ofrouting module interconnections between I/O and/or field signals (e.g.,signals 12, 24 above) using a software configuration tool, such as anapplication running on the computer 40 of FIG. 2A above), andconfiguring the routing module 100 by providing the set of definedinterconnections to a programmable logic device (e.g., PLD 170 above) onthe routing module 100. Although the exemplary methods 200, 300, and 400are illustrated and described hereinafter in the form of a series ofacts or events, it will be appreciated that the various methods of theinvention are not limited by the illustrated ordering of such acts orevents except as specifically set forth herein. In this regard, exceptas specifically provided in the claims, some acts or events may occur indifferent order and/or concurrently with other acts or events apart fromthose acts and ordering illustrated and described herein, and not allillustrated steps may be required to implement a process or method inaccordance with the present invention. The methods, moreover, may beimplemented in hardware, software, or combinations thereof, in order toprovide the described functionality, wherein these methods can bepracticed in hardware and/or software of the above describedprogrammable routing modules 100 serving to host a configuration tool,or in external devices including computers or other forms of logic,hardware, or software in any single or multiple entities operativelyassociated with the module 100 directly or through a network or othercommunications means, wherein the invention is not limited to thespecific applications and implementations illustrated and describedherein.

In FIG. 6, the routing module programming method 200 includes obtainingI/O connection information at 202, for instance by prompting a user forcatalog numbers or other identifying indicia representative of the I/Omodules or other I/O components 22 in the control system 20 with whichthe programmed module 100 is to interface for interconnecting I/Osignals 24. At 204, information is obtained for the field connection102, such as connector types, etc. With this information, the user maybe presented with a graphical interconnection definition environmentwith which the user defines the desired set of routing moduleinterconnections at 206. In one implementation, the interconnectiondefinition at 206 may be done manually with the user selecting each I/Opoint for each connector 102, 104 or in a semi automatic way whereby theprogrammer chooses a quantity of digital inputs, outputs/analoginputs/outputs, etc., to be assigned to each connector 102, 104 withmanual assignment of other I/O points individually. Alternatively, theinterconnection definition at 206 may be accomplished in a fullyautomatic way in which groups of points are assigned generically to a“standard” connector 102, 104, and the assignments take placeautomatically. At 208, the software configuration tool may thenoptionally check or confirm the validity of the defined set ofinterconnections and indicate any errors to the user, and may also printor otherwise render a graphical representation or “proof page” forverification of the defined configuration before proceeding.

At 210, the method 200 provides for programming the module 100 accordingto the defined set of routing interconnections by providing theinterconnections to the programmable logic device 170 on the routingmodule 100. The actual programming may be done simply throughprogramming the PLD 170 or thereafter by the PLD performing one or moreconfiguration acts with respect to the interconnection system 110, suchas by blowing fuses, burning traces, setting switch states, etc. Inother embodiments, an external device may perform the actual boardprogramming, for instance, by application or suitable terminal voltagesto blow specific fuses on the module 100, etc. At 212 and 214, themethod 200 may also include generating a code representing the set ofdefined interconnections, and storing the code on the module 100. Inaddition, the method 200 may further include generating a graphicalrepresentation at 216 (e.g., printing out an interconnection drawing,generating a CAD file, etc.) that depicts the defined set ofinterconnections for documentation of the control system setup.

FIG. 7 illustrates another exemplary programming method 300 in which apreexisting code is obtained at 302 representing a desired set ofrouting module interconnections. This may be obtained, for example, froma programmed module 100, from a data store of such configuration codesin a software package, or other suitable source, including manual entryof such a code by a user. At 304, a programmable routing module 100 isprogrammed according to the code, with the software performing anysuitable translation of the code into a set of defined interconnectionsin order to program a PLD 170 on the module 100 or to otherwise programthe module 100 to implement the desired interconnections represented bythe code.

FIG. 8 illustrates another exemplary module programming method 400,which is particularly useful in modifying an existing configuration,such as when a portion of the controlled process 14 or the controlsystem 20 is changed requiring reconfiguration of an installed module100. In the method 400, the definition of the routing moduleinterconnections begins at 402 with a code being obtained from therouting module 100 or elsewhere that represents the current set ofinterconnections. A graphical representation of the current set ofinterconnections is generated at 404 according to the code, and a useris allowed at 406 to modify the interconnections in order to define anew set of routing module interconnections between the I/O and/or fieldsignals 24, 12. The method 400 may then include optionally confirmingthe validity of the defined set of interconnections at 408. The module100 is then configured at 410 according to the new set of definedinterconnections, and a code is generated at 412 representing the set ofnewly defined interconnections. The code is then stored at 414 on themodule 100 and a graphical representation of the configuration may thenbe generated at 416 before the method 400 ends.

The above examples are merely illustrative of several possibleembodiments of various aspects of the present invention, whereinequivalent alterations and/or modifications will occur to others skilledin the art upon reading and understanding this specification and theannexed drawings. In particular regard to the various functionsperformed by the above described components (assemblies, devices,systems, circuits, and the like), the terms (including a reference to a“means”) used to describe such components are intended to correspond,unless otherwise indicated, to any component, such as hardware,software, or combinations thereof, which performs the specified functionof the described component (i.e., that is functionally equivalent), eventhough not structurally equivalent to the disclosed structure whichperforms the function in the illustrated implementations of theinvention. In addition, although a particular feature of the inventionmay have been disclosed with respect to only one of severalimplementations, such feature may be combined with one or more otherfeatures of the other implementations as may be desired and advantageousfor any given or particular application. Also, to the extent that theterms “including”, “includes”, “having”, “has”, “with”, or variantsthereof are used in the detailed description and/or in the claims, suchterms are intended to be inclusive in a manner similar to the term“comprising”.

1. A programmable routing module for interconnecting field wiring with acontrol system, the routing module comprising: a field connectionadapted to connect a plurality of field signals from a controlledprocess to the routing module; an I/O connection adapted to connect aplurality of I/O signals from a control system to the routing module; aconfigurable interconnection system coupled with the field connectionand with the I/O connection, the configurable interconnection systembeing selectively configurable to electrically couple particular fieldand I/O signals with one another according a defined set ofinterconnections, and store a code representing the set ofinterconnections.
 2. The programmable routing module of claim 1, whereinthe configurable interconnection system is configurable more than once.3. The programmable routing module of claim 1, wherein the configurableinterconnection system is configurable only once.
 4. The programmablerouting module of claim 1, wherein the module comprises a printedcircuit board with holes formed between top and bottom sides of theboard, and wherein the configurable interconnection system comprises: aplurality of conductive pads formed on top and bottom sides of the boardproximate the holes formed in the board with the conductive pads onopposite ends of the individual holes being electrically isolated andspaced from one another; a plurality of conductive traces formed on thetop and bottom sides of the board coupling the I/O and field signals toselect groups of the conductive pads with pads on opposite ends of theholes being connected by conductive traces to a unique pair of signals;and a plurality of conductive pins positioned in specific holes toelectrically connect pads on opposite ends of the specific holes toelectrically connect the corresponding signals.
 5. The programmablerouting module of claim 4, wherein the conductive pins are removableallowing reconfiguration of the routing module.
 6. The programmablerouting module of claim 1, wherein the configurable interconnectionsystem comprises a programmable logic device coupled with the fieldconnection and with the I/O connection, the programmable logic devicebeing configurable to selectively operatively couple particular fieldand I/O signals with one another according to the defined set ofinterconnections.
 7. The programmable routing module of claim 6, whereinthe programmable logic device stores the code representing the set ofinterconnections.
 8. The programmable routing module of claim 6, whereinthe programmable logic device is operative to perform a Booleanoperation on at least two particular field and/or I/O signals togenerate at least one output and to provide the output to the fieldconnection or the I/O connection.
 9. The programmable routing module ofclaim 6, comprising a communications interface operatively coupled withthe programmable logic device for communicative connection of theprogrammable logic device with an external device.
 10. The programmablerouting module of claim 1, comprising at least one driver circuit withan input selectively electrically coupleable to a particular field orI/O signal and with an output selectively electrically coupleable toanother particular field or I/O signal.
 11. The programmable routingmodule of claim 1, comprising at least one logic circuit with two ormore inputs selectively electrically coupleable to particular fieldand/or I/O signals and with at least one output selectively electricallycoupleable to particular field and/or I/O signals, the logic circuitbeing operative to perform a Boolean operation on the inputs to derivethe at least one output.
 12. The programmable routing module of claim 1,further comprising an expansion connection coupled to the fieldconnection and to the I/O connection, the expansion connection beingcoupleable to a second programmable routing module to route at leastsome of the field and/or I/O signals to the second programmable routingmodule.
 13. The programmable routing module of claim 1, wherein themodule comprises a printed circuit board, and wherein the fieldconnection comprises one or more board mounted cable connectorsoperatively coupleable to field wiring cables.
 14. The programmablerouting module of claim 1, wherein the module comprises a printedcircuit board, and wherein the I/O connection comprises one or moreboard mounted cable connectors operatively coupleable to I/O wiringcables.
 15. The programmable routing module of claim 1, wherein themodule comprises a printed circuit board, and wherein the I/O connectioncomprises a plurality of board mounted pins extending outward from oneside of the board and spaced in a predetermined pattern to allowinsertion of extended portions of the pins into receiving sockets of oneor more I/O terminal bases of the control system for electricalconnection to a plurality of I/O signals.
 16. A method of configuring arouting module for interconnecting field wiring with a control systemaccording to claim 1, the method comprising: defining a set of routingmodule interconnections between I/O and/or field signals using asoftware configuration tool; and configuring the routing module byproviding the set of routing module interconnections to a programmablelogic device on the routing module to establish a desired set ofinterconnections between a plurality of field signals from a controlledprocess and a plurality of I/O signals from the control system.
 17. Themethod of claim 16, further comprising: generating a code representingthe set of routing module interconnections; and storing the code in theprogrammable logic device.
 18. The method of claim 16, wherein definingthe set of routing module interconnections comprises: obtaining a codefrom the routing module that represents a current set ofinterconnections; generating a graphical representation of the currentset of interconnections according to the code; allowing a user to modifythe interconnections to define a new set of routing moduleinterconnections between I/O and/or field signals; and whereinconfiguring the routing module comprises providing the new set ofrouting module interconnections to the programmable logic device on therouting module.
 19. The method of claim 16, further comprising:generating a graphical representation of the set of routing moduleinterconnections.
 20. A system for configuring a muting module forinterconnecting field wiring with a control system according to claim 1,comprising: means for defining a set of routing module interconnectionsbetween I/O and/or field signals using a software configuration tool;and means for configuring the routing module by providing the set ofrouting module interconnections to a programmable logic device on therouting module to establish a desired set of interconnections between aplurality of field signals from a controlled process and a plurality ofI/O signals from the control system.